Basic Welding Filler Metal Technology: Lesson Ii Common Electric Arc Welding Processes

Lesson 2 - Common Electric Arc Welding Processes
Page 1 of 1
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
BASIC
WELDING FILLER METAL
TECHNOLOGY
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
A Correspondence Course
Lesson 5
Welding Filler Metals
for Stainless Steels
Lesson 6
Carbon & Low Alloy
Steel Filler Metals GMAW,GTAW,SAW
LESSON II
COMMON ELECTRIC ARC
WELDING PROCESSES
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
ESAB
ESAB Welding &

Cutting Products
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
COPYRIGHT 2000 THE ESAB GROU
http://www.esabna.com/EUWeb/AWTC/Lesson2_1.htm
12/2/03
Lesson 1
The Basics of Arc
Welding
TABLE OF CONTENTS
LESSON II
COMMON ELECTRIC ARC WELDING
PROCESSES
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
Lesson 5
Lesson 6
Carbon & Low Alloy
Page 1 of 1
Section Nr.
Section Title
Page
2.1
INTRODUCTION ..............................................................................
2.2
SHIELDED METAL ARC WELDING ...............................................
2.2.1
Equipment & Operation .....................................................................
2.2.2
Welding Power Sources ....................................................................
2.2.3
Electrode Holder................................................................................
2.2.4
Ground Clamp ...................................................................................
2.2.5
Welding Cables .................................................................................
2.2.6
Coated Electrodes ............................................................................
2.3
GAS-TUNGSTEN ARC WELDING ..................................................
2.3.1
Equipment & Operation .....................................................................
2.3.2
Power Sources ..................................................................................
2.3.3
Torches..............................................................................................
10
2.3.4
Shielding Gases ................................................................................
11
2.3.5
Electrodes .........................................................................................
12
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
2.3.6
Summary ...........................................................................................
13
Lesson 8
Hardsurfacing
Electrodes
2.4.4
Lesson 9
Estimating &
Comparing Weld
Metal Costs
2.4
GAS METAL ARC WELDING ..........................................................
13
2.4.1
Current Density ..................................................................................
14
2.4.2
Metal Transfer Modes ........................................................................
15
2.4.3
Equipment and Operation ..................................................................
17
Power Source....................................................................................
18
2.4.5
Wire Feeder ......................................................................................
19
2.4.6
Welding Gun ......................................................................................
20
2.4.7
Shielding Gases ................................................................................
21
2.4.7.1
Short Circuiting Transfer ....................................................
22
2.4.7.2
Spray Arc Transfer ............................................................
23
Lesson 10
Filler Metals
12/2/03
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
Lesson 5
Lesson 6
Carbon & Low Alloy
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Page 1 of 1
TABLE OF CONTENTS
LESSON II - Con't.
Section Nr.
Section Title
2.4.7.3
Page
Pulse Spray Transfer .........................................................
23
2.4.8
Electrodes .........................................................................................
23
2.5
FLUX CORED ARC WELDING .......................................................
24
2.5.1
Self-Shielded Process .......................................................................
24
2.5.2
Gas Shielded Process.......................................................................
25
2.5.3
Current Density ..................................................................................
26
2.5.4
Equipment .........................................................................................
26
2.5.5
Power Source....................................................................................
26
2.5.6
Wire Feeder ......................................................................................
26
2.5.7
Welding Guns ....................................................................................
26
2.5.8
Shielding Gases ................................................................................
27
2.6
SUBMERGED ARC WELDING .......................................................
27
2.6.1
Submerged Arc Flux ..........................................................................
28
2.6.2
The Welding Gun ...............................................................................
28
2.6.3
Power Sources ..................................................................................
28
2.6.4
Equipment .........................................................................................
28
2.6.5
Electrodes .........................................................................................
29
2.6.6
Summary ...........................................................................................
29
2.7
ELECTROSLAG AND ELECTROGAS WELDING ..........................
30
2.7.1
Electroslag Welding...........................................................................
30
2.7.2
Flux ...................................................................................................
30
2.7.3
Process .............................................................................................
30
2.7.4
Equipment.........................................................................................
31
2.7.5
Summary ..........................................................................................
31
Appendix A - GLOSSARY OF TERMS .................................................................
32
Lesson 10
Filler Metals
12/2/03
Page 1 of 1
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
LESSON II
COMMON ELECTRIC ARC WELDING PROCESSES

2.1
INTRODUCTION
After much experimentation by others in the early 1800's, an Englishman named Wilde
obtained the first electric welding patent in 1865. He successfully joined two small pieces of
iron by passing an electric current through both pieces producing a fusion weld. Approximately
twenty years later, Bernado, a Russian, was granted a patent for an electric arc welding
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
process in which he maintained an arc between a carbon electrode and the pieces to be
joined, fusing the metals together as the arc was manually passed over the joint to be welded.
2.1.0.1
During the 1890's, arc welding was accomplished with bare metal electrodes that
were consumed in the molten puddle and became part of the weld metal. The welds were of
Lesson 5
poor quality due to the nitrogen and oxygen in the atmosphere forming harmful oxides and
nitrides in the weld metal. Early in the Twentieth Century, the importance of shielding the arc
from the atmosphere was realized. Covering the electrode with a material that decomposed in
the heat of the arc to form a gaseous shield appeared to be the best method to accomplish
Lesson 6
Carbon & Low Alloy
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
this end. As a result, various methods of covering electrodes, such as wrapping and dipping,
were tried. These efforts culminated in the extruded coated electrode in the mid-1920's,
greatly improving the quality of the weld metal and providing what many consider the most
significant advance in electric arc welding.
2.1.0.2
Since welding with coated electrodes is a rather slow procedure, more rapid
welding processes were developed. This lesson will cover the more commonly used electric
arc welding processes in use today.
2.2
SHIELDED METAL ARC WELDING
Shielded Metal Arc Welding*, also known as manual metal arc welding, stick welding, or
electric arc welding, is the most widely used of the various arc welding processes. Welding is
performed with the heat of an electric arc that is maintained between the end of a coated metal
Lesson 9
Estimating &
Comparing Weld
Metal Costs
electrode and the work piece (See Figure 1). The heat produced by the arc melts the base
metal, the electrode core rod, and the coating. As the molten metal droplets are transferred
across the arc and into the molten weld puddle, they are shielded from the atmosphere by the
gases produced from the decomposition of the flux coating. The molten slag floats to the top
Lesson 10
Filler Metals
of the weld puddle where it protects the weld metal from the atmosphere during solidification.
12/2/03
Page 1 of 1
Lesson 1
The Basics of Arc
Welding
LESSON II
Other functions of the coating are to provide
arc stability and control bead shape. More
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
COATING
information on coating functions will be

CORE ROD
covered in subsequent lessons.

*
Shielded Metal Arc Welding (SMAW) is the

terminology approved by the American
Welding Society.
SHIELDING
GASES
WELD METAL
Equipment & Operation - One
2.2.1
reason for the wide acceptance of the SMAW

process is the simplicity of the necessary equipment.
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
WORK PIECE
SHIELDED METAL ARC WELDING
FIGURE 1
The equipment consists of the following items. (See

Figure 2)
Lesson 5
Lesson 6
Carbon & Low Alloy
1.
Welding power source
2.
Electrode holder
3.
Ground clamp
4.
Welding cables and connectors
5.
Accessory equipment (chipping

hammer, wire brush)
6.
2.2.2
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
SOLIDIFIED
SLAG
MOLTEN
POOL
AC OR DC
POWER
SOURCE
ELECTRODE
CABLE
ELECTRODE
HOLDER
ELECTRODE
WORK
GROUND
CABLE
SHIELDED METAL ARC WELDING CIRCUIT
Protective equipment (helmet, gloves, etc.)
FIGURE 2
Welding Power Sources - Shielded metal arc welding may utilize either
alternating current (AC) or direct current (DC), but in either case, the power source selected
must be of the constant current type. This type of power source will deliver a relatively constant
amperage or welding current regardless of arc length variations by the operator (See Lesson I,
Section 1.9). The amperage determines the amount of heat at the arc and since it will remain
relatively constant, the weld beads produced will be uniform in size and shape.
Lesson 8
Hardsurfacing
Electrodes
2.2.2.1
Whether to use an AC, DC, or AC/DC power source depends on the type of welding
to be done and the electrodes used. The following factors should be considered:
1. Electrode Selection - Using a DC power source allows the use of a greater range
Lesson 9
Estimating &
Comparing Weld
Metal Costs
of electrode types. While most of the electrodes are designed to be used on AC or

DC, some will work properly only on DC.
2. Metal Thickness - DC power sources may be used for welding both heavy
sections and light gauge work. Sheet metal is more easily welded with DC
Lesson 10
Filler Metals
because it is easier to strike and maintain the DC arc at low currents.
12/2/03
Page 1 of 1
Lesson 1
The Basics of Arc
Welding
LESSON II
3. Distance from Work - If the distance from the work to the power source is great,
AC is the best choice since the voltage drop through the cables is lower than with
Lesson 2
Common Electric
Arc Welding
Processes
DC. Even though welding cables are made of copper or aluminum (both good
conductors), the resistance in the cables becomes greater as the cable length
increases. In other words, a voltage reading taken between the electrode and the
work will be somewhat lower than a reading taken at the output terminals of the
power source. This is known as voltage drop.
Lesson 3
Covered Electrodes
for Welding
Mild Steels
4. Welding Position (See Appendix A - Glossary of Terms) - Because DC may be

operated at lower welding currents, it is more suitable for overhead and vertical
welding than AC. AC can successfully be used for out-of-position work if proper
electrodes are selected.
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
5. Arc Blow - When welding with DC, magnetic fields are set up throughout the
weldment. In weldments that have varying thickness and protrusions, this magnetic
field can affect the arc by making it stray or fluctuate in direction. This condition is
especially troublesome when welding in corners. AC seldom causes this problem
Lesson 5
because of the rapidly reversing magnetic field produced.

2.2.2.2
Combination power sources that produce both AC and DC are available and
provide the versatility necessary to select the proper welding current for the application.
Lesson 6
Carbon & Low Alloy
2.2.2.3
When using a DC power source, the question of whether to use electrode negative
or positive polarity arises. Some electrodes operate on both DC straight and reverse polarity,
and others on DC negative or DC positive polarity only. Direct current flows in one direction in
an electrical circuit and the direction of current flow and the composition of the electrode
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
coating will have a definite effect on the welding arc and weld bead. Figure 3 shows the
connections and effects of straight and reverse polarity.
2.2.2.4
Electrode negative (-) produces welds with shallow penetration; however, the
electrode melt-off rate is high. The weld bead is rather wide and shallow as shown at "A" in
Lesson 8
Hardsurfacing
Electrodes
Figure 3. Electrode
positive (+)
DC
POWER SOURCE
produces welds with

deep penetration
Lesson 9
Estimating &
Comparing Weld
Metal Costs
and a narrower weld
HIGHER BURN-OFF RATE,

LESS PENETRATION
DC
POWER SOURCE
DEEP PENETRATION,
LOW BURN-OFF RATE
ELECTRODE
ELECTRODE
bead as shown at
"B" in Figure 3.
WORK PIECE
STRAIGHT POLARITY
Lesson 10
Filler Metals
WORK PIECE
REVERSE POLARITY
FIGURE 3
COPYRIGHT 1998 THE ESAB GROUP, INC
12/2/03
Page 1 of 1
Lesson 1
The Basics of Arc
Welding
LESSON II
2.2.2.5
While polarity affects the penetration and burn-off rate, the electrode coating also
has a strong influence on arc characteristics. Performance of individual electrodes will be
Lesson 2
Common Electric
Arc Welding
Processes
discussed in succeeding lessons.
2.2.3
Electrode Holder - The electrode holder connects to the welding cable and con-
ducts the welding current to the electrode. The insulated handle is used to guide the electrode
Lesson 3
Covered Electrodes
for Welding
Mild Steels
over the weld joint and feed the electrode over the weld joint and feed the electrode into the
weld puddle as it is consumed. Electrode holders are available in different sizes and are rated
on their current carrying capacity.
2.2.4
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
piece. It may be connected directly to the work or to the table or fixture upon which the work is
positioned. Being a part of the welding circuit, the ground clamp must be capable of carrying
the welding current without overheating due to electrical resistance.
2.2.5
Lesson 5
Ground Clamp - The ground clamp is used to connect the ground cable to the work
Welding Cables - The electrode cable and the ground cable are important parts of
the welding circuit. They must be very flexible and have a tough heat-resistant insulation.
Connections at the electrode holder, the ground clamp, and at the power source lugs must be
soldered or well crimped to assure low electrical resistance. The cross-sectional area of the
cable must be sufficient size to carry the welding current with a minimum of voltage drop.
Lesson 6
Carbon & Low Alloy
Increasing the cable length necessitates increasing the cable diameter to lessen resistance
and voltage drop. The table in Figure 4 lists the suggested American Wire Gauge (AWG)
cable size to be used for various welding currents and cable lengths.
Welding
Service
Range
(Amperes)
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
20 to 180
30 to 250
60 to 375
80 to 500
100 to 600
Lesson 8
Hardsurfacing
Electrodes
Total Cable Length (Ground Lead Plus Electrode Lead)

Up to 50 ft.
Cable
Voltage
Size
Drop
#3
#2
#0
#00
#00
1.8
1.8
1.7
1.8
2.0
Up to 100 ft.
Cable
Voltage
Size
Drop
Up to 250 ft.
Cable
Voltage
Size
Drop
Up to 500 ft.
Cable
Voltage
Size
Drop
#2
#1
#0
#000
#0000
#1
#0
#00
#0000
...
#0
#0
#000
#0000
...
2.9
2.5
3.0
2.5
2.5
5.7
5.0
5.9
5.0
...
9.1
9.9
9.3
9.9
Voltage
Drop
Figured
At
180 Amps
200 Amps
300 Amps
400 Amps
500 Amps
Voltage drops indicated do not include any drop caused by poor connection, electrode holder, or work metal
FIGURE 4
Lesson 9
Estimating &
Comparing Weld
Metal Costs
2.2.6
Coated Electrodes - Various types of coated electrodes are used in shielded
metal arc welding. Electrodes used for welding mild or carbon steels are quite different than
those used for welding the low alloys and stainless steels. Details on the specific types will be
covered in subsequent lessons.
Lesson 10
Filler Metals
12/2/03
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Page 1 of 1
LESSON II
2.3
GAS TUNGSTEN ARC WELDING
Gas Tungsten Arc Welding* is a welding process performed using the heat of an arc
established between a nonconsumable tungsten electrode and the work piece. See Figure 5.
The electrode, the arc, and the area surrounding the molten weld puddle are protected from
the atmosphere by an inert gas shield. The electrode is not consumed in the weld puddle as in
shielded metal arc welding. If a filler metal is
Lesson 3
Covered Electrodes
for Welding
Mild Steels
necessary, it is added to the leading

the molten puddle as shown in
2.3.0.1
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
TRAVEL
DIRECTION
produces exceptionally clean welds

no slag is produced, the chance
TUNGSTEN
ELECTRODE
inclusions in the weld metal is

and the finished weld requires
and Helium, the primary
shielding gases employed,
are inert gases. Inert gases
do not chemically combine
Lesson 6
Carbon & Low Alloy
with other elements and
FILLER
METAL
therefore, are used to exclude
INERT GAS
SHIELD
WORK PIECE
GAS TUNGSTEN ARC WELDING
the reactive gases, such as oxygen and

nitrogen, from forming compounds that could
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
SHIELDING GAS
NOZZLE
ARC
virtually no cleaning. Argon
Lesson 5
TORCH
Gas tungsten arc welding
FIGURE 5
be detrimental to the weld metal.

2.3.0.2
Gas tungsten arc welding may be used for welding almost all metals mild steel,
low alloys, stainless steel, copper and copper alloys, aluminum and aluminum alloys, nickel
and nickel alloys, magnesium and magnesium alloys, titanium, and others. This process is
Lesson 8
Hardsurfacing
Electrodes
most extensively used for welding aluminum and stainless steel alloys where weld integrity is of
the utmost importance. Another use is for the root pass (initial pass) in pipe welding, which
requires a weld of the highest quality. Full penetration without an excessively high inside bead
is important in the root pass, and due to the ease of current control of this process, it lends
Lesson 9
Estimating &
Comparing Weld
Metal Costs
itself to control of back-bead size. For high quality welds, it is usually necessary to provide an
inert shielding gas inside the pipe to prevent oxidation of the inside weld bead.
Lesson 10
Filler Metals
Gas Tungsten Arc Welding (GTAW) is the current terminology approved by the American Welding Society,
formerly known as "TIG" (Tungsten Inert Gas) welding.
12/2/03
Page 1 of 1
Lesson 1
The Basics of Arc
Welding
LESSON II
2.3.0.3
Gas tungsten arc welding lends itself to both manual and automatic operation. In
manual operation, the welder holds the torch in one hand and directs the arc into the weld joint.
Lesson 2
Common Electric
Arc Welding
Processes
The filler metal is fed manually into the leading edge of the puddle. In automatic applications,
the torch may be automatically moved over a stationary work piece or the torch may be
stationary with the work moved or rotated in relation to the torch. Filler metal, if required, is
also fed automatically.
Lesson 3
Covered Electrodes
for Welding
Mild Steels
2.3.1
EQUIPMENT AND OPERATION - Gas tungsten arc welding may be accomplished
with relatively simple equipment, or it may require some highly sophisticated components.
Choice of equipment depends upon the type of metal being joined, the position of the weld
being made, and the quality of the weld metal necessary for the application. The basic equip-
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
Lesson 5
Lesson 6
Carbon & Low Alloy
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
ment consists of the following:

1.
The power source
2.
Electrode holder (torch)
3.
Shielding gas
4.
Tungsten electrode
5.
Water supply when necessary
6.
Ground cable
7.
Protective equipment
Figure 6 shows a basic gas tungsten arc welding schematic.
REGULATOR
FLOW METER
GAS HOSE (WATER COOLED ONLY)
TORCH
GAS COOLED ONLY

* COMPOSITE CABLE
WELDING CABLE
WATER COOLER
Lesson 8
Hardsurfacing
Electrodes
WORK
POWER
SOURCE
Lesson 9
Estimating &
Comparing Weld
Metal Costs
* COMPOSITE CABLE
GAS COOLED TORCH.
CURRENT IN & GAS IN.
WATER
TO
TORCH
WATER
FROM
TORCH
WATER COOLED TORCH.

CURRENT IN & WATER OUT
GROUND CABLE
SHIELDING
GAS SUPPLY
GAS TUNGSTEN ARC WELDING CONNECTION SCHEMATIC

FIGURE 6
Lesson 10
Filler Metals
12/2/03
Lesson 1
The Basics of Arc
Welding
Page 1 of 1
LESSON II
Power Sources - Both AC and DC power sources are used in gas tungsten arc
2.3.2
welding. They are the constant current type with a drooping volt-ampere curve. This type of
Lesson 2
Common Electric
Arc Welding
Processes
power source produces very slight changes in the arc current when the arc length (voltage) is
varied. Refer to Lesson I, Section 1.9.
2.3.2.1
Lesson 3
Covered Electrodes
for Welding
Mild Steels
The choice between an AC or DC welder depends on the type and thickness of the
metal to be welded. Distinct differences exist between AC and DC arc characteristics, and if
DC is chosen, the polarity also becomes an important factor. The effects of polarity in GTAW
are directly opposite the effects of polarity in SMAW as described in paragraphs 2.2.2.3
through 2.2.2.5. In SMAW, the distribution of heat between the electrode and work, which
determines the penetration and weld bead width, is controlled mainly by the ingredients in the
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
flux coating on the electrode. In GTAW where no flux coating exists, heat distribution between
the electrode and the work is controlled solely by the polarity. The choice of the proper welding
current will be better understood by analyzing each type separately. The chart in Figure 7 lists
current recommendations.
Lesson 5
Lesson 6
Carbon & Low Alloy
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
WELDING CURRENT
Material &
Thickness
DCEN
Aluminum
Under 1/8"
Over 1/8"
2
2&3
Magnesium
Under 1/16"
Over 1/16"
DCEP
SHIELDING GAS
AC
High Freq.
Argon
Helium
Ar/He
1
1
1
1
2
3
1
1
1
1
Carbon Steel
Under 1/8"
Over 1/8"
1
1
1
1
Stainless Steel
Under 1/8"
Over 1/8"
1
1
Copper
Under 1/8"
Over 1/8"
1
1
Nickel Alloys
Under 1/8"
Over 1/8"
1
1
Titanium
Under 1/8"
Over 1/8"
2
2
1
1.
2.
3.
3
2
2
1
2
1
Preferred Choice - Manual Welding

Preferred Choice - Automatic Welding
Second Choice - Automatic Welding
CURRENT/SHIELDING GAS SELECTION, TUNGSTEN GAS ARC WELDING

FIGURE 7
Lesson 10
Filler Metals
COPYRIGHT 1998 THE ESAB GROUP, I
12/2/03
Lesson 1
The Basics of Arc
Welding
Page 1 of 1
LESSON II
Direct current electrode negative (DCEN) is produced when the electrode is
2.3.2.2
connected to the negative terminal of the power source. Since the electrons flow from the
Lesson 2
Common Electric
Arc Welding
Processes
electrode to the plate, approximately 70% of the heat of the arc is concentrated at the work,
and approximately 30% at the electrode end. This allows the use of smaller tungsten electrodes that produce a relatively narrow concentrated arc. The weld shape has deep penetration and is quite narrow. See Figure 8. Direct current electrode negative is suitable for weld-
Lesson 3
Covered Electrodes
for Welding
Mild Steels
ing most metals. Magnesium and aluminum have a refractory oxide coating on the surface that
must be physically removed immediately prior to welding if DCSP is to be used.
Direct current electrode positive (DCEP) is produced when the electrode is
2.3.2.3
connected to the positive terminal of the welding power source. In this condition, the electrons
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
flow from the work to the electrode tip, concentrating approximately 70% of the heat of the arc
at the electrode and 30% at the work. This higher heat at the electrode necessitates using
larger diameter tungsten to prevent it from melting and contaminating the weld metal. Since
the electrode diameter is larger and the heat is less concentrated at the work, the resultant
Lesson 5
weld bead is relatively wide and shallow. See Figure 8.

Electrode
Polarity
_
Lesson 6
Carbon & Low Alloy
GAS IONS
ELECTRON
FLOW
Direct Current
Straight Polarity
Electrode Negative
Deep
Penetration
Narrow
Bead
Medium Penetration
Alternating Current
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Penetration
+ _
Direct Current
Reverse Polarity
Electrode Positive
Medium Width
Bead
Shallow Penetration
Oxide
Cleaning
Heat
Concentration
None
At
Work
Good
Cleans Oxide
on Each Half
Cycle
Alternates Between
Electrode and Work
Maximum
At
Electrode
Wide Bead
EFFECTS OF CURRENT TYPE - GAS TUNGSTEN ARC WELDING
Lesson 8
Hardsurfacing
Electrodes
FIGURE 8
2.3.2.4
Aluminum and magnesium are two metals that have a heavy oxide coating that acts
as an insulator and must be removed before successful welding can take place. Welding with
Lesson 9
Estimating &
Comparing Weld
Metal Costs
electrode positive provides a good oxide cleaning action in the arc. If we were to study the
physics of the welding arc, we find that the electric current causes the shielding gas atoms to
lose some of their electrons. Since electrons are negatively charged, these gas atoms now
are unbalanced and have an excessive positive charge. As we learned in Lesson I, unlike
Lesson 10
Filler Metals
charges attract. These positively charged atoms (or positive ions as they are known in
COPYRIGHT 1998 THE ESAB GROUP, INC.
12/2/03
Page 1 of 1
Lesson 1
The Basics of Arc
Welding
LESSON II
chemical terminology) are attracted to the negative pole, in this case the work, at high velocity.
Upon striking the work surface, they dislodge the oxide coating permitting good electrical
Lesson 2
Common Electric
Arc Welding
Processes
conductivity for the maintenance of the arc, and eliminate the impurities in the weld metal that
could be caused by these oxides.
2.3.2.5
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
Direct current electrode positive is rarely used in gas-tungsten arc welding. Despite
the excellent oxide cleaning action, the lower heat input in the weld area makes it a slow
process, and in metals having higher thermal conductivity, the heat is rapidly conducted away
from the weld zone. When used, DCEP is restricted to welding thin sections (under 1/8") of
magnesium and aluminum.
2.3.2.6
Alternating current is actually a combination of DCEN and DCEP and is widely
used for welding aluminum. In a sense, the advantages of both DC processes are combined,
and the weld bead produced is a compromise of the two. Remember that when welding with
60 Hz current, the electron flow from the electrode tip to the work reverses direction 120 times
every second. Thereby, the intense heat alternates from electrode to work piece, allowing the
Lesson 5
use of an intermediate size electrode. The weld bead is a compromise having medium
penetration and bead width. The gas ions blast the oxides from the surface of aluminum and
magnesium during the positive half cycle. Figure 8 illustrates the effects of the different types
of current used in gas-tungsten arc welding.
Lesson 6
Carbon & Low Alloy
2.3.2.7
DC constant current power sources - Constant current power sources, used for
shielded metal arc welding, may also be used for gas-tungsten arc welding. In applications
where weld integrity is not of utmost importance, these power sources will suffice. With
machines of this type, the arc must be initiated by touching the tungsten electrode to the work
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
and quickly withdrawing it to maintain the proper arc length. This starting method
contaminates the electrode and blunts the point which has been grounded on the electrode
end. These conditions can cause weld metal inclusions and poor arc direction. Using a
power source designed for gas tungsten arc welding with a high frequency stabilizer will
Lesson 8
Hardsurfacing
Electrodes
eliminate this problem. The electrode need not be touched to the work for arc initiation.
Instead, the high frequency voltage, at very low current, is superimposed onto the welding
current. When the electrode is brought to within approximately 1/8 inch of the base metal, the
high frequency ionizes the gas path, making it conductive and a welding arc is established.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
The high frequency is automatically turned off immediately after arc initiation when using direct
current.
2.3.2.8
AC Constant Current Power Source - Designed for gas tungsten arc welding,
always incorporates high frequency, and it is turned on throughout the weld cycle to maintain a
Lesson 10
Filler Metals
stable arc. When welding with AC, the current passes through 0 twice in every cycle and the
12/2/03
Page 1 of 1
Lesson 1
The Basics of Arc
Welding
LESSON II
arc must be reestablished each time it does so. The oxide coating on metals, such as
aluminum and magnesium, can act much like a rectifier as discussed in Lesson I. The positive
Lesson 2
Common Electric
Arc Welding
Processes
half-cycle will be eliminated if the arc does not reignite, causing an unstable condition.
Continuous high frequency maintains an ionized path for the welding arc, and assures arc reignition each time the current changes direction. AC is extensively used for welding aluminum
and magnesium.
Lesson 3
Covered Electrodes
for Welding
Mild Steels
2.3.2.9
AC/DC Constant Current Power Sources - Designed for gas tungsten arc
welding, are available, and can be used for welding practically all metals. The gas tungsten
arc welding process is usually chosen because of the high quality welds it can produce. The
metals that are commonly welded with this process, such as stainless steel, aluminum and
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
some of the more exotic metals, cost many times the price of mild steel; and therefore, the
power sources designed for this process have many desirable features to insure high quality
welds. Among these are:
1.
Lesson 5
Remote current control, which allows the operator to control welding amperage
with a hand control on the torch, or a foot control at the welding station.
2.
Automatic soft-start, which prevents a high current surge when the arc is
initiated.
Lesson 6
Carbon & Low Alloy
3.
flow before, during and for an adjustable length of time after the weld is completed.
4.
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Shielding gas and cooling water solenoid valves, which automatically control
Spot-weld timers, which automatically control all elements during each

spot-weld cycle.
Other options and accessories are also available.

2.3.2.10
Power sources for automatic welding with complete programmable output are also
available. Such units are used extensively for the automatic welding of pipe in position. The
Lesson 8
Hardsurfacing
Electrodes
welding current is automatically varied as the torch travels around the pipe. Some units
provide a pulsed welding current where the amperage is automatically varied between a low
and high several times per second. This produces welds with good penetration and improved
weld bead shape.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
2.3.3
Torches - The torch is actually an electrode holder that supplies welding current to
the tungsten electrode, and an inert gas shield to the arc zone. The electrode is held in a
collet-like clamping device that allows adjustment so that the proper length of electrode protrudes beyond the shielding gas cup. Manual torches are designed to accept electrodes of 3
Lesson 10
Filler Metals
12/2/03
Page 1 of 1
Lesson 1
The Basics of Arc
Welding
LESSON II
inch or 7 inch lengths. Torches may be either air or water-cooled. The air-cooled types actually are cooled to a degree by the shielding gas that is fed to the torch head through a compos-
Lesson 2
Common Electric
Arc Welding
Processes
ite cable. The gas actually surrounds the copper welding cable, affording some degree of
cooling. Water-cooled torches are usually used for applications where the welding current
exceeds 200 amperes. The water inlet hose is connected to the torch head. Circulating
around the torch head, the water leaves the torch via the current-in hose and cable assembly.
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Cooling the welding cable in this manner allows the use of a smaller diameter cable that is
more flexible and lighter in weight.
2.3.3.1
The gas nozzles are made of ceramic materials and are available in various sizes
and shapes. In some heavy duty, high current applications, metal water-cooled nozzles are
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
used.
2.3.3.2
A switch on the torch is used to energize the electrode with welding current and start
the shielding gas flow. High frequency current and water flow are also initiated by this switch if
the power source is so equipped. In many installations, these functions are initiated by a foot
Lesson 5
control that also is capable of controlling the welding current. This method gives the operator
full control of the arc. The usual welding method is to start the arc at a low current, gradually
increase the current until a molten pool is achieved, and welding begins. At the end of the
weld, current is slowly decreases and the arc extinguished, preventing the crater that forms at
Lesson 6
Carbon & Low Alloy
the end of the weld when the arc is broken abruptly.
2.3.4
Shielding Gases - Argon and helium are the major shielding gases used in gas
tungsten arc welding. In some applications, mixtures of the two gases prove advantageous.
To a lesser extent, hydrogen is mixed with argon or helium for special applications.
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
2.3.4.1
Argon and helium are colorless, odorless, tasteless and nontoxic gases. Both are
inert gases, which means that they do not readily combine with other elements. They will not
burn nor support combustion. Commercial grades used for welding are 99.99% pure. Argon
is .38% heavier than air and about 10 times heavier than helium. Both gases ionize when
Lesson 8
Hardsurfacing
Electrodes
present in an electric arc. This means that the gas atoms lose some of their electrons that
have a negative charge. These unbalanced gas atoms, properly called positive ions, now
have a positive charge and are attracted to the negative pole in the arc. When the arc is
positive and the work is negative, these positive ions impinge upon the work and remove
Lesson 9
Estimating &
Comparing Weld
Metal Costs
surface oxides or scale in the weld area.

2.3.4.2
Argon is most commonly used of the shielding gases. Excellent arc starting and
ease of use make it most desirable for manual welding. Argon produces a better cleaning
action when welding aluminum and magnesium with alternating current. The arc produced is
Lesson 10
Filler Metals
12/2/03
Page 1 of 1
Lesson 1
The Basics of Arc
Welding
LESSON II
relatively narrow. Argon is more suitable for welding thinner material. At equal amperage,
helium produces a higher arc voltage than argon. Since welding heat is the product of volts
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
times amperes, helium produces more available heat at the arc. This makes it more suitable
for welding heavy sections of metal that have high heat conductivity, or for automatic welding
operations where higher welding speeds are required.
2.3.4.3
Argon-helium gas mixtures are used in applications where higher heat input and the
desirable characteristics of argon are required. Argon, being a relatively heavy gas, blankets
the weld area at lower flow rates. Argon is preferred for many applications because it costs
less than helium.
2.3.4.4
Helium, being approximately 10 times lighter than argon, requires flow rates of 2 to
3 times that of argon to satisfactorily shield the arc.

2.3.5
Electrodes - Electrodes for gas tungsten arc welding are available in diameters
from .010" to 1/4" in diameter and standard lengths range from 3" to 24". The most commonly
Lesson 5
used sizes, however, are the .040", 1/16", 3/32", and 1/8" diameters.
2.3.5.1
The shape of the tip of the electrode is an important factor in gas tungsten arc
welding. When welding with DCEN, the tip must be ground to a point. The included angle at
which the tip is ground varies with the application, the electrode diameter, and the welding
Lesson 6
Carbon & Low Alloy
current. Narrow joints require a relatively small included angle. When welding very thin
material at low currents, a needlelike point ground onto the smallest available electrode may
be necessary to stabilize the arc. Properly ground electrodes will assure easy arc starting,
good arc stability, and proper bead width.
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
2.3.5.2
When welding with AC, grinding the electrode tip is not necessary. When proper
welding current is used, the electrode will form a hemispherical end. If the proper welding
current is exceeded, the end will become bulbous in shape and possibly melt off to
contaminate the weld metal.
Lesson 8
Hardsurfacing
Electrodes
2.3.5.3
The American Welding Society has published Specification AWS A5.12-80 for
tungsten arc welding electrodes that classifies the electrodes on the basis of their chemical
composition, size and finish. Briefly, the types specified are listed below:
Lesson 9
Estimating &
Comparing Weld
Metal Costs
1) Pure Tungsten (AWS EWP) Color Code: Green

Used for less critical applications. The cost is low and they give good results at
relatively low currents on a variety of metals. Most stable arc when used on AC, either
balanced wave or continuous high frequency.
Lesson 10
Filler Metals
12/2/03
Lesson 1
The Basics of Arc
Welding
Page 1 of 1
LESSON II
2) 1% Thoriated Tungsten (AWS EWTh-1) Color Code: Yellow
Good current carrying capacity, easy arc starting and provide a stable arc. Less
Lesson 2
Common Electric
Arc Welding
Processes
susceptible to contamination. Designed for DC applications of nonferrous materials.

3) 2% Thoriated Tungsten (AWS EWTh-2) Color Code: Red
Longer life than 1% Thoriated electrodes. Maintain the pointed end longer, used for
light gauge critical welds in aircraft work. Like 1%, designed for DC applications for
Lesson 3
Covered Electrodes
for Welding
Mild Steels
nonferrous materials.
4) .5% Thoriated Tungsten (AWS EWTh-3) Color Code: Blue
Sometimes called "striped" electrode because it has 1.0-2.0% Thoria inserted in a
wedge-shaped groove throughout its length. Combines the good properties of pure
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
and thoriated electrodes. Can be used on either AC or DC applications.

5) Zirconia Tungsten (AWS EWZr) Color Code: Brown
Longer life than pure tungsten. Better performance when welding with AC. Melts more
Lesson 5
Lesson 6
Carbon & Low Alloy
easily than thoriam-tungsten when forming rounded or tapered tungsten end. Ideal for
applications where tungsten contamination must be minimized.
2.3.6
Summary - Gas Tungsten Arc Welding is one of the major welding processes
today. The quality of the welds produced and the ability to weld very thin metals are the major
features. The weld metal quality is high since no flux is used, eliminating the problem of slag
inclusions in the weld metal. It is used extensively in the aircraft and aerospace industry, where
high quality welds are necessary and also for welding the more expensive metals where the
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
weld defects become very costly. Metals as thin as .005" can be welded due to the ease of
controlling the current.
2.3.6.1
The major disadvantages of the process are that it is slower than welding with
consumable electrodes and is little used on thicknesses over 1/4" for this reason. Shielding
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
gas and tungsten electrode costs make the process relatively expensive.
2.4
Gas Metal Arc Welding* is an arc welding process that uses the heat of an electric arc
established between a consumable metal electrode and the work to be welded. The electrode
is a bare metal wire that is transferred across the arc and into the molten weld puddle. The
*
Lesson 10
Filler Metals
GAS METAL ARC WELDING
Gas Metal Arc Welding (GMAW) is the current technology approved by the American Welding Society.
Formerly known as "MIG" (Metal Inert Gas) Welding.
12/2/03
Page 1 of 1
Lesson 1
The Basics of Arc
Welding
LESSON II
wire, the weld puddle, and the area in the arc zone are protected from the atmosphere by a
gaseous shield. Inert gases, reactive gases, and gas mixtures are used for shielding. The
Lesson 2
Common Electric
Arc Welding
Processes
metal transfer mode is dependent on shielding gas choice and welding current level. Figure 9
is a sketch of the process showing the basic features.
TRAVEL
DIRECTION
WELDING WIRE
WELDING CABLE
Lesson 3
Covered Electrodes
for Welding
Mild Steels
SHIELDING GAS
SOLID WIRE
ELECTRODE
GAS NOZZLE
GAS SHIELD
CONTACT TIP
ARC
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
WELD METAL
WORK PIECE
MOLTEN POOL
GAS METAL ARC WELDING
Lesson 5
FIGURE 9
2.4.0.1
Lesson 6
Carbon & Low Alloy
Gas metal arc welding is a versatile process that may be used to weld a wide
variety of metals including carbon steels, low alloy steels, stainless steels, aluminum alloys,
magnesium, copper and copper alloys, and nickel alloys. It can be used to weld sheet metal or
relatively heavy sections. Welds may be made in all positions, and the process may be used
for semiautomatic welding or automatic welding. In semiautomatic welding, the wire feed
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
speed, voltage, amperage, and gas flow are all preset on the control equipment. The operator
needs merely to guide the welding gun along the joint at a uniform speed and hold a relatively
constant arc length. In automatic welding, the gun is mounted on a travel carriage that moves
along the joint, or the gun may be stationary with the work moving or revolving beneath it.
Lesson 8
Hardsurfacing
Electrodes
2.4.0.2
Practically all GMAW is done using DCEP (Electrode positive). This polarity
provides deep penetration, a stable arc and low spatter levels. A small amount of GMAW
welding is done with DCEN and although the melting rate of the electrode is high, the arc is
erratic. Alternating current is not used for gas metal arc welding.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
2.4.1
Current Density - To understand why gas metal arc welding can deposit weld
metal at a rapid rate, it is necessary that the term "current density" be understood. Figure 10
shows a 1/4" coated electrode and a 1/16" solid wire drawn to scale. Both are capable of
carrying 400 amperes. Notice that the area of the 1/16" wire is only 1/16 that of the core wire
Lesson 10
Filler Metals
of the coated electrode. We can say that the current density of the 1/16" wire is 16 times
12/2/03
Page 1 of 1
Lesson 1
The Basics of Arc
Welding
LESSON II
AREA = .049 SQ. IN.
greater than the current density

of the 1/4" wire at equal welding
Lesson 2
Common Electric
Arc Welding
Processes
currents. The resultant melt-off
CORE WIRE
A 16
If we were to increase the current
1/16"
through the 1/4" coated
Lesson 3
Covered Electrodes
for Welding
Mild Steels
AREA = .0031 SQ. IN.
rate of the solid wire is very high.
electrode to increase the current
FLUX
COATING
SOLID WIRE
density, the resistance heating

through the 14" electrode length would be
1/4"
COATED ELECTRODE
.049 .0031 = 16
excessive, and the rod would become so

hot that the coating would crack, rendering
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
Lesson 5
RELATIVE SIZE OF ELECTRODES FOR WELDING AT 400 AMPS
it useless. The 1/16" wire carries the high

FIGURE 10
current a distance of less than 3/4", the

approximate distance from the end of the contact tip to the arc.
2.4.2
Metal Transfer Modes
2.4.2.1
Spray transfer is a high current density process that rapidly deposits weld metal in
droplets smaller than the electrode diameter. They are propelled in a straight line from the
center of the electrode. A shielding gas mixture of Argon with 1% to 2% Oxygen is used for
Lesson 6
Carbon & Low Alloy
welding mild and low alloy steel, and pure Argon or Argon-Helium mixtures are used for welding aluminum, magnesium, copper, and nickel alloys. Welding current at which spray transfer
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
SPRAY
TRANSFER
GLOBULAR
TRANSFER
PULSE
TRANSFER
1
2
3
SHORT CIRCUITING ARC METAL TRANSFER
MODES OF METAL TRANSFER

FIGURE 11
Lesson 9
Estimating &
Comparing Weld
Metal Costs
takes place is relatively high and will vary with the metal being welded, electrode diameter, and
the shielding gas being used. Deposition rates are high and welding is usually limited to the
flat or horizontal fillet position. See Figure 11.
Lesson 10
Filler Metals
12/2/03
Lesson 1
The Basics of Arc
Welding
Page 1 of 1
LESSON II
2.4.2.2
Globular transfer takes place at lower welding currents than spray transfer. There
is a transition current where the transfer changes to globular even when shielding gases using
Lesson 2
Common Electric
Arc Welding
Processes
a high percentage of argon are used. When carbon dioxide (CO2) is used as a shielding gas,
the transfer is always globular. In globular transfer, a molten drop larger than the electrode
diameter forms on the end of the electrode, moves to the outer edge of the electrode and falls
into the molten puddle. Occasionally, a large drop will "short circuit" across the arc, causing
Lesson 3
Covered Electrodes
for Welding
Mild Steels
the arc to extinguish momentarily, and then instantaneously reignite. As a result, the arc is
somewhat erratic, spatter level is high, and penetration shallow. Globular transfer is not
suitable for out-of-position welding. See Figure 11.
2.4.2.3
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
Short circuiting transfer is a much used method in gas metal arc welding. It is
produced by using the lowest current-voltage settings and the smaller wires, usually .030",
.035", and .045" diameters. The low heat input makes this process ideal for sheet metal, outof-position work, and poor fit-up applications. Often called "short arc welding" because metal
transfer is achieved each time the wire actually short circuits (makes contact) with the weld
Lesson 5
puddle. This happens very rapidly. It is feasible for the short circuit frequency to be 20-200
times a second, but in practice, it occurs from 90-100 times a second. Each time the
electrode touches the puddle, the arc is extinguished. It happens so rapidly that it is visible
only on high speed films.
Lesson 6
Carbon & Low Alloy
2.4.2.4
Pulse transfer is a mode of metal transfer somewhat between spray and short
circuiting. The specific power source has built into it two output levels: a steady background
level, and a high output (peak) level. The later permits the transfer of metal across the arc.
This peak output is controllable between high and low values up to several hundred cycles per
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
second. The result of such a peak output produces a spray arc below the typical transition
current.
2.4.2.4.1 Figure 11 shows the transfer method. The arc is initiated by touching the wire to the
work. Upon initial contact, a bit of the wire melts off to form a molten puddle. The wire feeds
Lesson 8
Hardsurfacing
Electrodes
forward until it actually contacts the work again, as at 1 in Figure 11, and the arc is
extinguished. The short circuiting current causes the wire to neck down, as shown in 1, until it
melts off, as shown at 2. As soon as the wire is free of the puddle, the arc is reignited and a
molten ball forms at the end of the electrode, as at 3. The wire continues to move forward until
Lesson 9
Estimating &
Comparing Weld
Metal Costs
it makes contact with the puddle, and the cycle is repeated.

2.4.2.5
Gas metal arc spot welding is a variation of the process that allows spot welding
of thinner gauge metals, or of a thin gauge metal to a heavier section. The gun is placed
directly against the work and is equipped with a special nozzle to allow escape of the shielding
Lesson 10
Filler Metals
gas. When the trigger switch is actuated, the following sequence takes place. The shielding
12/2/03
Page 1 of 1
Lesson 1
The Basics of Arc
Welding
LESSON II
gas flows for a short interval before wire feeding starts; wire feeding starts; the arc is initiated
and continues for a preset time (usually a few seconds). The welding current and wire feeding
Lesson 2
Common Electric
Arc Welding
Processes
stops, and the shielding gas flows for a short interval before it automatically stops. The
process is also useful for tacking welding pieces in position prior to running the final weld
bead.
2.4.3
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
EQUIPMENT AND OPERATION - The equipment used for gas metal arc welding
is more complicated than that required for shielded metal arc welding. Initial cost is relatively
high, but the cost is rapidly amortized due to the savings in labor and overhead achieved by
the rapid weld metal deposition.
2.4.3.1
The equipment necessary for gas metal arc welding is listed below:
1) Power source
2) Wire feeder
3) Welding gun
Lesson 5
4) Shielding gas supply

5) Solid electrode wire
6) Protective equipment
Lesson 6
Carbon & Low Alloy
2.4.3.2
The basic equipment necessary for semiautomatic gas metal arc welding is shown
in Figure 12.
GAS HOSE
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
FLOWMETER
REGULATOR
TRIGGER
CONTROL LEAD
FEED ROLLS
WIRE SPOOL
WIRE FEEDER
VALVE
Lesson 8
Hardsurfacing
Electrodes
MAGNETIC
Lesson 9
Estimating &
Comparing Weld
Metal Costs
WELD CABLE
115V
WELDING GUN
CONTACTOR
_
+
SHIELDING
GAS
POWER
SOURCE
GROUND CABLE
WORK
SCHEMATIC DIAGRAM SEMI-AUTOMATIC GMAW EQUIPMENT
Lesson 10
Filler Metals
FIGURE 12
12/2/03
Page 1 of 1
Lesson 1
The Basics of Arc
Welding
LESSON II
2.4.4
Lesson 2
Common Electric
Arc Welding
Processes
Power Source - A direct current, constant voltage power source is recommended
for gas metal arc welding. It may be a transformer-rectifier or a rotary type unit. The lower
open circuit voltage and self-correcting arc length feature, as described in Lesson I, makes it
most suitable. Constant voltage power sources used for spray transfer welding and for flux
cored electrode welding (to be covered later) are the same. However, if the unit is to be used
for short-circuiting arc
Lesson 3
Covered Electrodes
for Welding
Mild Steels
welding, it must have

"slope" or slope control.
means of limiting the
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
high short-circuit current

that is characteristic of
this type welder. Figure
OPERATING POINT
V
O
L
T
S
20
15
10
5
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
SHORT CIRCUITING
CURRENT NO SLOPE
SHORT CIRCUITING CURRENT

WITH SLOPE
circuiting current.
200
2.4.4.1
If we were
short-arc welding at
Lesson 6
Carbon & Low Alloy
CONSTANT VOLTAGE V/A CURVE
13 shows the effect of

slope on the short-
Lesson 5
25
Slope control is a
approximately 150 amperes
400
600
800
1000
1200
1400
EFFECT OF SLOPE ON SHORT CIRCUITING CURRENT
FIGURE 13
and 18 volts, as shown in Figure 13,

and had no slope components in the power source, the current at short-circuit or when the wire
touches the work, would be over 1400 amperes. At this high current, a good length of the wire
would literally explode off the end, cause much spatter, and the arc would be erratic. With the
slope components in the circuit, the short-circuiting current is in the neighborhood of 400
amperes, and the molten ball is sort of pinched off the end of the wire more gently. For those
with an electrical background, it might be added that in some machines, slope is achieved by
adding a reactor in the AC secondary of the power source. In others, a slope resistor is added
Lesson 8
Hardsurfacing
Electrodes
in the DC output portion of the circuit. Slope may be adjustable for varying wire diameters or it
may be fixed, giving a good average value for .035" and .045" diameter wires, the two most
popular sizes.
2.4.4.2
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Another factor influencing the arc in short-circuiting welding is the rate that the
amperage reaches the short-circuiting current level. Using the example in Figure 13, we know
that the current goes from 150 amperes to 400 amperes during each shorting period. If we
were to plot the current rise on a graph, as in Figure 14, we would see that the current rise if
very rapid, as shown by the broken line.
Lesson 10
Filler Metals
12/2/03
Page 1 of 1
Lesson 1
The Basics of Arc
Welding
LESSON II
This rapid current rise can be
by using a device called an
Lesson 2
Common Electric
Arc Welding
Processes
(sometimes called a stabilizer)

output circuit of the welder. An
400 AMPS
WITHOUT INDUCTANCE
merely an iron core wound

turns of heavy wire. It does
current flow, but it acts
Lesson 3
Covered Electrodes
for Welding
Mild Steels
WITH INDUCTANCE
somewhat like a fly wheel or

damper by retarding the rate of
rise as shown by the solid
line. By preventing the
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
150 AMPS
rapid current rise, the arc
TIME - MILLISECONDS
EFFECT OF INDUCTANCE ON CURRENT RISE
FIGURE 14
Lesson 5
becomes smoother,
spatter is reduced, and
bead shape and
appearance are
improved. Because the inductor influences the time function, its design determines arc on-off
time, and short-circuit frequency. Some power sources have a selector that can switch in
several different inductance values to finely tune the arc.
Lesson 6
Carbon & Low Alloy
2.4.4.4
Welding power sources designed for gas metal arc welding have a 115 volt outlet to
provide power to operate the wire feeder. They also have a receptacle to receive the electrical
power required to close the main contactor in the power source, which turns on the welding
power to the welding gun when the gun trigger is actuated.
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
2.4.4.5
Additional advancements in equipment technology have introduced many new
models. Inverters, as well as microprocessor controls, have created the greatest attention. In
addition, multipurpose machines have provided the user with greater flexibility with a variety of
capabilities.
Lesson 8
Hardsurfacing
Electrodes
2.4.4.6
Global competition will continue to have a profound influence on future
advancements in arc welding equipment. As energy prices rise, greater demands for more
efficient equipment will follow.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
2.4.5
Wire Feeder - When welding with a constant voltage power source, as is the case
in most gas metal arc welding applications, the prime function of the wire feeder is to deliver
the welding wire to the arc at a very constant speed. Since the wire feed speed determines
the amperage, and the amperage determines the amount of heat at the arc, inconsistent wire
Lesson 10
Filler Metals
feed speed will produce welds of varying penetration and bead width. Advanced electronics
COPYRIGHT 1998 THE ESAB GROUP, INC.
12/2/03
Lesson 1
The Basics of Arc
Welding
Page 1 of 1
LESSON II
technology makes it possible to design motor speed controls that will produce the same
speed, even though the load on the motor varies or the input voltage to the motor may fluctuate.
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
2.4.5.1
power sources. In this case, the motor speed automatically varies to increase or decrease the
wire feed speed as the arc length varies to maintain a constant voltage.
2.4.5.2
The wire feeder also controls the main contactor in the power source for safety
reasons. This assures that the welding wire will only be energized when the switch on the
welding gun is depressed.
2.4.5.3
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
A limited amount of gas metal arc welding is performed with constant current type
The flow of shielding gas is controlled by a solenoid valve (magnetic valve) in the
wire feeder to turn the shielding gas on and off when the gun switch is actuated. Most feeders
utilize a dynamic breaking circuit to quickly stop the motor at the end of a weld to prevent a
long length of wire protruding from the gun when the weld is terminated. Most feeders have a
burn-back circuit that allows the welding current to stay on for a short period of time after wire
Lesson 5
feeding has stopped, to allow the wire to burn back exactly the right amount for the next arc
initiation.
2.4.5.4
The feed rolls, sometimes called drive rolls, pull the wire off the spool or reel, and
push it through a feed cable or conduit to the welding gun. These rolls must usually be
Lesson 6
Carbon & Low Alloy
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
changed to accommodate each different wire diameter, although some rolls are designed to
feed a combination of sizes.
2.4.6
to deliver the welding wire, welding current, and shielding gas to the welding arc. Guns are
available for semi-automatic operation and for automatic operation, where they are fixed in the
automatic welding head.
2.4.6.1
Lesson 8
Hardsurfacing
Electrodes
Welding Gun - The function of the welding gun, sometimes referred to as a torch, is
Guns for GMAW have several characteristics in common. All have a copper alloy
shielding gas nozzle, that delivers the gas to the arc area in a nonturbulent, angular pattern to
prevent aspiration of air. The nozzle may be water cooled for semiautomatic welding at high
amperage and for automatic welding where the arc time is of long duration. Welding current is
transferred to the welding wire as the wire travels through the contact tip or contact tube
located inside the gas nozzle (Refer to Figure 9). The hole in the contact tip through which the
Lesson 9
Estimating &
Comparing Weld
Metal Costs
wire passes is only a few thousandths of an inch larger than the wire diameter. A worn contact
tip will result in an erratic arc due to poor current transfer. Figure 15 shows a few different
semiautomatic gun configurations that are commonly used for GMAW.
Lesson 10
Filler Metals
12/2/03
Page 1 of 1
Lesson 1
The Basics of Arc
Welding
LESSON II
Lesson 2
Common Electric
Arc Welding
Processes
CURVED NECK
Lesson 3
Covered Electrodes
for Welding
Mild Steels
PISTOL TYPE
SELF CONTAINED
PULL TYPE
SEMI-AUTOMATIC GMAW GUN TYPES
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
FIGURE 15
2.4.6.2
The curved neck or "goose neck" type is probably the most commonly used. It
allows the best access to a variety of weld joints. The wire is pushed to this type of gun by the
Lesson 5
feed rolls in the wire feeder through a feed cable or conduit that usually is 10 or 12 feet in
length. The shielding gas hose, welding current cable, and trigger switch leads are supplied
with the welding gun.
2.4.6.3
Lesson 6
Carbon & Low Alloy
difficult to reach joints. The pistol type is also a "push" type gun and is more suitable for gas
metal arc spot welding applications.
2.4.6.4
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
The pistol type gun is similar to the curved neck type, but is less adaptable for
The self contained type has an electric motor in the handle and feed rolls that pull the
wire from a 1 or 2 pound spool mounted on the gun. The need for a long wire feed cable is
eliminated, and wire feed speed may be controlled by the gun. Guns of this type are often
used for aluminum wire up to .045" diameter, although they may also be used for feeding steel
or other hard wires.
2.4.6.5
The pull type gun has either an electric motor or an air motor mounted in the handle
that is coupled to a feeding mechanism in the gun. The spool of wire is located in the control
cabinet that may be located as far as fifty feet from the gun. When feeding such long
distances, a set of "push" rolls located in the control cabinet assist in feeding the wire. This
Lesson 9
Estimating &
Comparing Weld
Metal Costs
then becomes known as a push-pull feed system and is especially useful in feeding the softer
wires such as aluminum.
2.4.7
SHIELDING GASES - In gas metal arc welding, there are a variety of shielding
gases that can be used, either alone or in combinations of varying degrees. The choice is
dependent on the type of metal transfer employed, the type and thickness of metal, the bead
Lesson 10
Filler Metals
12/2/03
Page 1 of 1
Lesson 1
The Basics of Arc
Welding
LESSON II
profile (See Figure 16), penetration, and speed of welding. In our discussion, we will deal with
the more common choices used for the various transfer processes.
Lesson 2
Common Electric
Arc Welding
Processes
FERROUS METALS
Lesson 3
Covered Electrodes
for Welding
Mild Steels
CO2
ARGON + CO2
NON-FERROUS METALS
ARGON + O2
ARGON
HELIUM
BEAD PROFILE
FIGURE 16
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
2.4.7.1
Short Circuiting Transfer - Straight carbon dioxide (CO2) is often used for short
circuiting arc welding because of its low cost. The deep penetration usually associated with
CO2 is minimized because of the low amperage and voltage settings used with this process.
Compared to other gas mixes, CO2 will produce a harsher arc and therefore, greater spatter
Lesson 5
levels. Usually, this is minimized by maintaining a short arc length and by careful adjustment of
the power supply inductance. The temperatures reached in welding will cause carbon dioxide
to decompose into carbon monoxide and oxygen. To reduce the possibility of porosity caused
by entrapped oxygen in the weld metal, it is wise to use electrodes that contain deoxidizing
Lesson 6
Carbon & Low Alloy
elements, such as silicon and manganese. If the current is increased above the short circuiting
range, the use of carbon dioxide tends to produce a globular transfer.
2.4.7.1.1 Mixing argon in proportions of 50-75% with carbon dioxide will produce a smoother
arc and reduce spatter levels. It will also widen the bead profile, reduce penetration, and
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
encourage "wetting". Wetting, i.e., a uniform fusion, along with joining edges of the base metal
and the weld metal, minimizes the weld imperfection known as undercutting (See Figure 17).
UNDERCUT
WETTING
FIGURE 17
2.4.7.1.2 The 75% Argon/25 CO2 mixture is often chosen for short circuit welding of thin
sections, whereas the 50-50 combination works well on thicker sections.
2.4.7.1.3 It should be noted that shielding gases can affect the metallurgy of the weld metal.
As an example, a combination of argon and carbon dioxide may be used for welding stainless
Lesson 10
Filler Metals
steel, but as the carbon dioxide breaks down, excessive carbon may be transferred into the
12/2/03
Page 1 of 1
Lesson 1
The Basics of Arc
Welding
LESSON II
weld metal. Corrosion resistance in stainless steel is reduced as the carbon content
increases. To counteract this possibility, a less reactive mixture of 90% helium - 7-1/2% argon
Lesson 2
Common Electric
Arc Welding
Processes
- 2-1/2% CO2 is sometimes chosen. This combination, known as a trimix, provides good arc
stability and wetting.
2.4.7.2
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Spray Arc Transfer - Pure argon produces a deep constricted penetration at the
center of the bead with much shallower penetration at the edges (Figure 16). Argon performs
well on nonferrous metals, but when used on ferrous metals, the transfer is somewhat erratic
with the tendency for the weld metal to move away from the center line. To make argon suitable for spray transfer on ferrous metals, small additions of 1 to 5% oxygen have proven to
provide remarkable improvements. The arc stabilizes, becomes less spattery, and the weld
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
metal wets out nicely. If the percentage of argon falls below 80%, it is impossible to achieve
true spray transfer.
2.4.7.2.1 Pure helium or combinations of helium and argon are used for welding nonferrous
metals. The bead profile will broaden as the concentration of helium increases.
Lesson 5
2.4.7.3
Pulse Spray Transfer - The selection of shielding gas must be adequate enough to
support a spray transfer. Material type, thickness, and welding position are essential variables
in selecting a particular shielding gas. The following is a list of recommended gases:
Lesson 6
Carbon & Low Alloy
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
2.4.8
Lesson 8
Hardsurfacing
Electrodes
Carbon Steel
Argon/CO2/O2/He (He less than 50%)
Alloy Steel
Argon/CO2/O2/He (He less than 50%)
Stainless
Argon/O2/CO2 (CO2 max. 2%)
Copper, Nickel, & Cu-Ni Alloys
Argon/Helium
Aluminum
Argon/Helium
Electrodes - The solid electrodes used in GMAW are of high purity when they come
from the mill. Their chemistry must be closely controlled and some types purposely contain
high levels of deoxidizers for use with CO2 shielding.
2.4.8.1
The electrode manufacturer draws down the electrode to a finished diameter that,
with GMAW, is usually quite small. Diameters from .030" thru 1/16" are common.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
2.4.8.2
Most steel GMAW electrodes are copper plated as a means of protecting the
surface. The copper inhibits rusting, provides smooth feeding, and helps electrical
conductivity.
Lesson 10
Filler Metals
2.4.8.3
Information on types and classifications will be covered in a future lesson.
12/2/03
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Page 1 of 1
LESSON II
2.5
FLUX CORED ARC WELDING
Flux Cored Arc Welding (FCAW) is quite similar to GMAW as far as operation and
equipment are concerned. The major difference is that FCAW utilizes an electrode that is very
different from the solid electrode used in GMAW. The flux cored electrode is a fabricated
electrode and as the name implies, flux material is deposited into its core. The flux cored
electrode begins as a flat metal strip that is formed first into a "U" shape. Flux and alloying
Lesson 3
Covered Electrodes
for Welding
Mild Steels
elements are deposited into the "U" and then the shape is closed into a tubular configuration
by a series of forming rolls.
2.5.0.1
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
The flux cored electrode is a continuous electrode that is fed into the arc where it is
melted and transferred into the molten puddle. As in GMAW, the flux cored process depends
on a gas shield to protect the weld zone from detrimental atmospheric contamination. With
FCAW, there are two primary ways this is accomplished (See Figure 18). The gas is either
applied externally, in which case the electrode is referred to as a gas shielded flux cored
electrode, or it is generated from the decomposition of gas forming ingredients contained in
Lesson 5
Lesson 6
Carbon & Low Alloy
the electrode's core. In this instance, the electrode is known as a self-shielding flux cored
electrode. In addition to the gas shield, the flux cored electrode produces a slag covering for
CONTACT TIP
CONTACT TIP
GAS CUP
INSULATED
GUIDE TUBE
GAS SHIELD
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
FLUX CORE
FLUX CORE
Lesson 8
Hardsurfacing
Electrodes
SELF SHIELDED
GAS SHIELDED
FLUX-CORED ARC WELDING
FIGURE 18
Lesson 9
Estimating &
Comparing Weld
Metal Costs
further protection of the weld metal as it cools. The slag is manually removed with a wire brush
or chipping hammer.
2.5.1
Lesson 10
Filler Metals
Self Shielded Process - The main advantage of the self shielding method is that
its operation is somewhat simplified because of the absence of external shielding equipment.
COPYRIGHT 1998 THE ESAB GRO
12/2/03
Page 1 of 1
Lesson 1
The Basics of Arc
Welding
LESSON II
Although self shielding electrodes have been developed for welding low alloy and stainless
steels, they are most widely used on mild steels. The self shielding method generally uses a
Lesson 2
Common Electric
Arc Welding
Processes
long electrical stick-out (distance between the contact tube and the end of the unmelted electrode) commonly from one to four inches. Electrical resistance is increased with the long
extension, preheating the electrode before it is fed into the arc. This enables the electrode to
burn off at a faster rate and increases deposition. The preheating also decreases the heat
Lesson 3
Covered Electrodes
for Welding
Mild Steels
available for melting the base metal, resulting in a more shallow penetration than the gas
shielded process.
2.5.1.1
A major drawback of the self shielded process is the metallurgical quality of the
deposited weld metal. In addition to gaining its shielding ability from gas forming ingredients
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
in the core, the self shielded electrode contains a high level of deoxidizing and denitrifying
alloys, primarily aluminum, in its core. Although the aluminum performs well in neutralizing the
affects of oxygen and nitrogen in the arc zone, its presence in the weld metal will reduce
ductility and impact strength at low temperatures. For this reason, the self shielding method is
Lesson 5
usually restricted to less critical applications.

2.5.1.2
The self shielding electrodes are more suitable for welding in drafty locations than
the gas shielded types. Since the molten filler metal is on the outside of the flux, the gases
formed by the decomposing flux are not totally relied upon to shield the arc from the
Lesson 6
Carbon & Low Alloy
atmosphere. The deoxidizing and denitrifying elements in the flux further help to neutralize the
affects of nitrogen and oxygen present in the weld zone.
2.5.2
The Gas Shielded Process - A major advantage with the shielded flux cored
electrode is the protective envelope formed by the auxiliary gas shield around the molten
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
puddle. This envelope effectively excludes the natural gases in the atmosphere without the
need for core ingredients such as aluminum. Because of this more thorough shielding, the
weld metallurgy is cleaner which makes this process suitable for welding not only mild steels,
but also low alloy steels in a wide range of strength and impact levels.
Lesson 8
Hardsurfacing
Electrodes
2.5.2.1
The gas shielded method uses a shorter electrical stickout than the self shielded
process. Extensions from 1/2" to 3/4" are common on all diameters, and 3/4" to 1-1/2" on
larger diameters. Higher welding currents are also used with this process, enabling high
deposition rates to be reached. The auxiliary shielding helps to reduce the arc energy into a
Lesson 9
Estimating &
Comparing Weld
Metal Costs
columnar pattern. The combination of high currents and the action of the shielding gas
contributes to the deep penetration inherent with this process. Both spray and globular
transfer are utilized with the gas shielded process.
Lesson 10
Filler Metals
12/2/03
Lesson 1
The Basics of Arc
Welding
Page 1 of 1
LESSON II
2.5.3
Current Density - Flux cored arc welding utilizes the same principles of current
density, as explained in section 2.4.1, but there is one significant difference between the flux
Lesson 2
Common Electric
Arc Welding
Processes
cored electrode and the solid electrode. With the flux cored electrode, the granular core
ingredients are poor electrical conductors and therefore, the current is carried primarily
through the outer metal sheathing. When an equal diameter cross section of the two are compared (See Figure
Lesson 3
Covered Electrodes
for Welding
Mild Steels
CURRENT PATH
19), it is seen that the flux cored electrode has

a smaller current carrying area than the solid
electrode. This greater concentration of
current in a smaller area increases the
burnoff rate.
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
2.5.3.1
When all other factors are equal,
the deposition rate of the flux cored

electrode is somewhat higher than the
Lesson 5
1/16" FLUX-CORED
ELECTRODE
solid electrode.
2.5.4
1/16" SOLID
ELECTRODE
FIGURE 19
EQUIPMENT - The equipment used for flux cored arc welding is the same as
shown previously in Section 2.3.2.2, Figure 12, with the exception that the self shielded
method does not need the external gas apparatus.
Lesson 6
Carbon & Low Alloy
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
2.5.4.1
Flux cored arc welding is done with direct current. All of the gas shielded electrodes
are designed for DCEP operation. The self shielded electrodes are either designed
specifically for DCEN or DCEP.
2.5.5
Power Source - The recommended power source is the direct current constant
voltage type. The constant current type can be used but with less satisfactory results.
2.5.6
Wire Feeder - The function of the wire feeder in FCAW is the same as discussed in
the section on GMAW. Since the flux cored electrode is tubular in construction, precautions
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
must be taken not to flatten the electrode. To facilitate feeding by means other than pressure
alone, specially designed feed rolls with knurled or grooved surfaces are used. Some feeders
use four feed rolls rather than two to minimize unit pressure on the electrode.
2.5.7
The Welding Gun - As compared to GMAW, the main difference in FCAW welding
guns is in those used with the self shielding process. The gun is somewhat more compact due
to the absence of an external gas shielding nozzle. Since the self shielding process normally
requires a longer electrode extension, the self shielding gun may have an insulated guide tube
(Refer back to Figure 18) to give stability to the electrode. Water cooled guns are available for
Lesson 10
Filler Metals
high duty semi-automatic welding and for automatic welding.
COPYRIGHT 1998 THE ESAB GROUP, I
12/2/03
Page 1 of 1
Lesson 1
The Basics of Arc
Welding
LESSON II
2.5.7.1
Flux cored welding generates fumes, that for environmental reasons, must be
removed from the welding area. This is usually done with an external exhaust system, but
Lesson 2
Common Electric
Arc Welding
Processes
welding guns with internal fume extractors have been developed. They are heavier than the
regular gun and must be properly maintained so that the extracting mechanism does not
disturb the shielding gas.
2.5.8
Lesson 3
Covered Electrodes
for Welding
Mild Steels
shielding of the flux cored electrode. The other commonly used gas is a mixture of 75% Argon
and 25% CO2.
2.5.8.1
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
Lesson 5
A carbon dioxide shield produces deep penetration and the transfer is globular. As
previously discussed, CO2 will dissociate in the heat of the arc. To counteract this
characteristic, deoxidizing elements are added to the core ingredients of the electrode. The
deoxidizers react to form solid oxide compounds that float to the surface as part of the slag
covering.
2.5.8.2
The addition of Argon to CO2 will increase the wetting action, produce a smooth arc
arc, and reduce spatter. The transfer is spray-like, and the penetration is somewhat less than
with the straight carbon dioxide.
2.5.8.3
Lesson 6
Carbon & Low Alloy
SHIELDING GASES - Carbon dioxide is the most widely used gas for auxiliary
While some flux cored electrodes are designed to operate well on both the 100%
CO2 or the 75/25 mixture, others are formulated specifically for the CO2 shield or the Argon/
CO2 mixture. If the recommended gas is not used with these electrodes, the weld chemistry
may be affected. The reason for this is that inert gas, such as Argon, does not react with the
other elements; therefore, allowing them to be transferred across the arc into the weld metal.
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
An electrode designed for CO2 shielding contains deoxidizing elements, such as silicon and
manganese. If a high percentage of Argon is used in the shielding medium, a large portion of
these elements may pass into the weld metal causing the weld metallurgy to be less ductile
than intended.
Lesson 8
Hardsurfacing
Electrodes
2.5.8.3
The opposite happens with electrodes formulated for a 75/25 mixture. These
electrodes are usually designed for high yield and tensile strength. If a high percentage of CO2
is used with them, the CO2 may react with the elements needed to attain these strength levels,
thereby preventing them from passing into the weld metal.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
2.6
SUBMERGED ARC WELDING
Submerged Arc Welding (SAW) is different from the previously explained arc welding
processes in that the arc is not visible. The arc is submerged beneath loose granular flux. A
Lesson 10
Filler Metals
continuous electrode is fed by automatic drive rolls through an electrode holder where current
12/2/03
Page 1 of 1
Lesson 1
The Basics of Arc
Welding
LESSON II
is picked up at the contact tube. The electrode moves into the loose flux and the arc is
initiated. The flux is deposited from a separate container that moves at the same pace as the
Lesson 2
Common Electric
Arc Welding
Processes
electrode assuring complete coverage (See Figure 20).

2.6.1
Submerged Arc Flux - The flux helps form the molten puddle, slows the cooling
rate, and acts as a protective shield. The flux, which is in close contact with the arc, is fused
Lesson 3
Covered Electrodes
for Welding
Mild Steels
into a slag cover and that which is not fused is collected for reuse. The flux can contain alloying
elements that, when molten, will pass into the weld metal affecting the metallurgy. Some fluxes
are specifically prepared for their alloy altering capabilities while others, known as neutral
fluxes, are chosen when a minimal alloy change is desired. Although these latter fluxes are
called "neutral", they still have the ability to slightly alter the weld chemistry.
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
FLUX HOPPER
Lesson 5
Lesson 6
Carbon & Low Alloy
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
LOOSE GRANULAR FLUX
ELECTRODE
BASE
METAL
MOLTEN PUDDLE
FUSED SLAG COVER
SOLIDIFIED WELD METAL
SUBMERGED ARC WELDING
FIGURE 20
2.6.2
The Welding Gun - Although there are hand-held welding guns for the submerged
arc process, the majority of SAW is done with fully automatic equipment. The basic compo-
Lesson 8
Hardsurfacing
Electrodes
nents include a wire feeder, a power source, a flux delivery system, and in some instances, an
automatic flux recovery system.
2.6.3
Lesson 9
Estimating &
Comparing Weld
Metal Costs
may be a DC rectifier or generator of either the constant current or constant voltage variety.
The power source must be rated for high current output. When current requirements exceed
the value of a single machine, two or more of the same type may be connected in parallel.
2.6.4
Lesson 10
Filler Metals
Power Sources - The power source can be a constant current AC transformer, or it
Equipment - Most submerged arc welding is done with DCEP because it provides
easy arc starting, deep penetration and excellent bead shape. DCEN provides the highest
12/2/03
Page 1 of 1
Lesson 1
The Basics of Arc
Welding
LESSON II
deposition rates but minimum penetration. Alternating current is often used as a trailing arc in
tandem arc applications. In this type of application, the leading DCEP arc provides deep
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
penetration, and the closely trailing AC arc provides high deposition with a minimum of arc
blow.
2.6.5
Electrodes - A variety of ferrous and nonferrous electrodes are used in submerged
arc welding. They are usually solid electrodes refined with the appropriate alloys at the steel
mill, and then shipped to electrode manufacturers where they are drawn down to a specific
diameter and packaged. There is another type of sub arc electrode known as a composite
electrode, that is fabricated in the same manner as a flux cored electrode. A chief advantage
of this type is that the alloying elements can be added to the core of the electrode more
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
cheaply than a steel mill can produce those same alloys in a solid form. The electrodes for
SAW vary in diameter from 1/16 inch to 1/4 inch with the larger diameters being the most
widely used.
2.6.6
Lesson 5
Summary - Submerged arc welding has some advantages over other welding
processes. Since the radiance of the arc is blanketed by the loose flux, there is no need for a
protective welding hood (although safety glasses are recommended), there is no spatter and
only a very minimal amount of fumes escape from under the blanket. High welding currents,
quite commonly in the 300 to 1600 ampere range, are used. These high currents, combined
Lesson 6
Carbon & Low Alloy
with fast travel speeds, make SAW a high deposition process that is especially suitable for
applications that require a series of repetitious welds. Some setups allow two or more electrodes to be fed simultaneously into the joint, further increasing the deposition rate and speed.
2.6.6.1
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Although SAW has these advantages, it does have some limitations. The flux must
be deposited and collected for every welding pass. This requires additional equipment and
handling. Also because of the loose flux, the process is limited to the flat and horizontal
positions. The equipment for SAW is commonly quite bulky which limits its mobility, and
although the process works well on thick materials, it usually is not satisfactory for thin gauge
Lesson 8
Hardsurfacing
Electrodes
material. The process requires care in the operation. The amperages commonly used may
cause excessive heat buildup in the base metal, that may result in distortion or brittleness.
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals
12/2/03
Lesson 1
The Basics of Arc
Welding
Lesson 2
Common Electric
Arc Welding
Processes
Page 1 of 1
LESSON II
2.7
ELECTROSLAG AND ELECTROGAS WELDING
Electroslag Welding (ESW) and Electrogas Welding (EGW) comprise only a minor portion
of all welding done in the country, but they are uniquely adapted to certain applications,
primarily the joining of very thick materials. The joining of a 12 inch material along a 40 foot
line is not an uncommon application for the Electroslag process.
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Electroslag Welding (See Figure 21) is technically not an arc welding process,
2.7.1
although it utilizes a current carrying consumable electrode. The only time there is an arc
between the electrode and the work piece is when current is initially charged through the
electrode. This initial charge heats a layer of loose flux that becomes molten and extinguishes
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
the arc.
WATER INLET/OUTLET
ELECTRODE
COPPER SHOE
Lesson 5
GUIDE TUBE
(CONSUMABLE GUIDE METHOD)
BASE METAL
Lesson 6
Carbon & Low Alloy
MOLTEN FLUX
WELD POOL
SOLIDIFIED METAL
ELECTROSLAG WELDING
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
FIGURE 21
2.7.2
Flux - The flux used in ESW is high in electrical resistance. As current is applied,
enough heat is generated from this resistance to keep the flux, base metal, and electrode in a
Lesson 8
Hardsurfacing
Electrodes
molten state. This axis of the weld joint is on a vertical plane. The two pieces of metal, usually
of the same thickness, are positioned so that there is an opening between them. One or more
electrodes are fed into the opening through a welding bead that travels vertically as the joint is
filled. To contain the molten puddle, water cooled copper shoes or dams are placed on the
Lesson 9
Estimating &
Comparing Weld
Metal Costs
sides of the vertical cavity. As the weld joint solidifies, the dams move vertically so as to
always remain in contact with the molten puddle.
2.7.3
Process - A variation of ESW is the consumable guide method. The process is the
same with this method except that the guide tube that feeds the electrode to the molten pool is
Lesson 10
Filler Metals
12/2/03
Page 1 of 1
Lesson 1
The Basics of Arc
Welding
LESSON II
also consumed. The chief advantage with this method is the elimination of the electrode
holder which must move vertically with the weld pool. Also since the guide tube is consumed,
Lesson 2
Common Electric
Arc Welding
Processes
the deposition rate is slightly increased with this method.

2.7.4
Equipment - The equipment used in ESW is all automatic and of special design.
The power source may use either AC or DC current. The electrode may be either solid or flux
Lesson 3
Covered Electrodes
for Welding
Mild Steels
cored, although if the flux cored is used, it must be specially formulated so as not to contain its
normal amount of slag forming ingredients.
2.7.5
Summary - Electrogas Welding is similar to ESW as far as the mechanical as-
pects are concerned. The equipment is automatic, the welding head travels vertically, and the
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
molten puddle is retained by shoes on the sides of the joint. The difference is that Electrogas
Welding utilizes an arc and it is externally gas shielded. The power source is also limited to
DC operation. The electrodes used in EGW can be either solid or flux cored.
Lesson 5
Lesson 6
Carbon & Low Alloy
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals
12/2/03
Lesson 1
The Basics of Arc
Welding
LESSON II
APPENDIX A
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
LESSON II - GLOSSARY OF TERMS
Arc Blow
Straight
Reverse
Polarity
Lesson 5
- Deviation of the direction of the welding arc caused by magnetic fields in the
work piece when welding with direct current.
Polarity
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
Page 1 of 1
- Welding condition when the electrode is connected to the negative terminal

and the work is connected to the positive terminal of the welding power source.
- Welding condition when the electrode is connected to the positive terminal

and the work is connected to the negative terminal of the welding power
source.
Slag
- The brittle mass that forms over the weld bead on welds made with coated
electrodes, flux cored electrodes, submerged arc welding and other slag
producing welding processes. Welds made with the gas metal arc and the
Lesson 6
Carbon & Low Alloy
gas tungsten arc welding processes are slag free.
Manual Arc
Welding
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Semi-Automatic
Welding
speed and the rate the electrode is fed into the arc.
- Welding with a continuous solid wire or flux cored electrode where the wire
feed speed, shielding gas flow rate, and voltage are preset on the equipment,
and the operator guides the hand held welding gun along the joint to be
Lesson 8
Hardsurfacing
Electrodes
welded.
Slag
Lesson 9
Estimating &
Comparing Weld
Metal Costs
- Welding with a coated electrode where the operator's hand controls travel
Inclusion
Root Pass
- A weld defect where slag is entrapped in the weld metal before it can float to
the surface.
- The initial pass in a multi-pass weld, usually requiring 100% penetration.
Lesson 10
Filler Metals
12/2/03
Lesson 1
The Basics of Arc
Welding
Page 1 of 1
LESSON II
Gas Ions
- Shielding gas atoms that, in the presence of an electrical current, lose one or
more electrons and therefore, carry a positive electrical charge. The provide
Lesson 2
Common Electric
Arc Welding
Processes
a more electrically conductive path for the arc between the electrode and the
work piece.
High
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Frequency
- (as applied to gas-tungsten arc welding)

An alternating current consisting of over 50,000 cycles per second at high
voltage, low amperage that is superimposed on the welding circuit in GTAW
power sources. It ionizes a path for non-touch arc starting and stabilizes the
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
Lesson 5
arc when welding with alternating current.

Inert Gases
- Gases that are chemically inactive. They do not readily combine with other
elements.
Flux
- In arc welding, fluxes are formulations that, when subjected to the arc, act as
a cleaning agent by dissolving oxides, releasing trapped gases and slag and
generally cleaning the weld metal by floating the impurities to the surface
where they solidify in the slag covering. The flux also serves to reduce spatter
and contributes to weld bead shape. The flux may be the coating on the
Lesson 6
Carbon & Low Alloy
electrode, inside the electrode as in flux cored types, or in a granular form as

used in submerged arc welding.
Current
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Density
- The amperes per square inch of cross-sectional area of an electrode. High

current density results in high electrode melt-off rate and a concentrated, deep
penetrating arc.
Slope or Slope
Lesson 8
Hardsurfacing
Electrodes
Control
welding. Slope Control reduces the short circuiting current each time the
electrode touches the weld puddle (See Section 2.5.3).
Inductance
Lesson 9
Estimating &
Comparing Weld
Metal Costs
- A necessary feature in welding power sources used for short circuiting arc
- (as applies to short circuiting arc welding)

A feature in welding power sources designed for short circuiting arc welding
to retard the rate of current rise each time the electrode touches the weld
puddle.
Lesson 10
Filler Metals
12/2/03
Page 1 of 1
Lesson 1
The Basics of Arc
Welding
LESSON II
Contact Tip
- That part of a gas metal arc welding gun or flux cored arc welding gun that
transfers the welding current to the welding wire immediately before the wire
Lesson 2
Common Electric
Arc Welding
Processes
enters the arc.
Spray
Lesson 3
Covered Electrodes
for Welding
Mild Steels
Transfer
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
Globular
- Mode of metal transfer across the arc where the molten metal droplets are
smaller than the electrode diameter and are axially directed to the weld puddle.
Requires high voltage and amperage settings and a shielding gas of at least
80% argon.
Transfer
- Mode of metal transfer across the arc where a molten ball larger than the
electrode diameter forms at the tip of the electrode. On detachment, it takes
on an irregular shape and tumbles towards the weld puddle sometimes
shorting between the electrode and work at irregular intervals. Occurs when
using shielding gases other than those consisting of at least 80% argon and
Lesson 5
at medium current settings.
Pulse
Lesson 6
Carbon & Low Alloy
Transfer
- Mode of metal transfer somewhat between spray and short circuiting. The
specific power source has built into it two output levels: a steady background
level, and a high output (peak) level. The later permits the transfer of metal
across the arc. This peak output is controllable between high and low values
up to several hundred cycles per second. The result of such a peak output
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
produces a spray arc below the typical transition current.
Shortcircuiting
Transfer
Lesson 8
Hardsurfacing
Electrodes
Transfer takes place each time the electrode touches or short-circuits to the
weld puddle, extinguishing the arc. The short-circuiting current causes the
electrode to neck down, melt off, and then repeats the cycle.
Trimix or
Lesson 9
Estimating &
Comparing Weld
Metal Costs
- Mode of metal transfer in gas metal arc welding at low voltage and amperage.
Triple Mix
- A shielding gas consisting of approximately 90% helium, 7-1/2% argon, and

2-1/2% carbon dioxide used primarily for short-circuiting arc welding of
stainless steels. Maintains corrosion resistance of the stainless steel and
produces good wetting and excellent weld bead shape.
Lesson 10
Filler Metals
12/2/03
Page 1 of 1
Lesson 1
The Basics of Arc
Welding
LESSON II
Electrical
Lesson 2
Common Electric
Arc Welding
Processes
Lesson 3
Covered Electrodes
for Welding
Mild Steels
is the distance from the contact tip to the unmelted electrode end. Sometimes
called the "amount of wire in resistance". This distance influences melt-off
rate, penetration, and weld bead shape.
Out-of-Position
- Welds made in positions other than flat or horizontal fillets.
Welds
Weld
Lesson 4
Covered Electrodes
for Welding Low
Alloy Steels
- In any welding process using a solid or flux cored wire, the electrical stick-out
Stick-Out
Positions
FLAT
HORIZONTAL FILLET
Lesson 5
Lesson 6
Carbon & Low Alloy
VERTICAL
OVERHEAD
Lesson 7
Flux Cored Arc
Electrodes Carbon
Low Alloy Steels
Lesson 8
Hardsurfacing
Electrodes
HORIZONTAL
BUTT
POSITIONED FILLET
(FLAT)
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals
12/2/03

Basic Welding Filler Metal Technology: Lesson Ii Common Electric Arc Welding Processes

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Lesson 2 - Common Electric Arc Welding Processes

ESAB Welding &

Lesson 2 - Common Electric Arc Welding Processes

SHIELDED METAL ARC WELDING ...............................................

Equipment & Operation .....................................................................

Welding Power Sources ....................................................................

Ground Clamp ...................................................................................

Welding Cables .................................................................................

Coated Electrodes ............................................................................

GAS-TUNGSTEN ARC WELDING ..................................................

Equipment & Operation .....................................................................

Power Sources ..................................................................................

Shielding Gases ................................................................................

GAS METAL ARC WELDING ..........................................................

Current Density ..................................................................................

Metal Transfer Modes ........................................................................

Equipment and Operation ..................................................................

Wire Feeder ......................................................................................

Welding Gun ......................................................................................

Shielding Gases ................................................................................

Short Circuiting Transfer ....................................................

Spray Arc Transfer ............................................................

Lesson 2 - Common Electric Arc Welding Processes

Pulse Spray Transfer .........................................................

FLUX CORED ARC WELDING .......................................................

Self-Shielded Process .......................................................................

Gas Shielded Process.......................................................................

Current Density ..................................................................................

Wire Feeder ......................................................................................

Welding Guns ....................................................................................

Shielding Gases ................................................................................

SUBMERGED ARC WELDING .......................................................

Submerged Arc Flux ..........................................................................

The Welding Gun ...............................................................................

Power Sources ..................................................................................

ELECTROSLAG AND ELECTROGAS WELDING ..........................

Appendix A - GLOSSARY OF TERMS .................................................................

Lesson 2 - Common Electric Arc Welding Processes

COMMON ELECTRIC ARC WELDING PROCESSES

SHIELDED METAL ARC WELDING

COPYRIGHT 1998 THE ESAB GROU

Lesson 2 - Common Electric Arc Welding Processes

information on coating functions will be

covered in subsequent lessons.

Shielded Metal Arc Welding (SMAW) is the

Equipment & Operation - One

reason for the wide acceptance of the SMAW

The equipment consists of the following items. (See

Welding power source

Welding cables and connectors

Accessory equipment (chipping

Protective equipment (helmet, gloves, etc.)

of electrode types. While most of the electrodes are designed to be used on AC or

because it is easier to strike and maintain the DC arc at low currents.

COPYRIGHT 1998 THE ESAB GROU

Lesson 2 - Common Electric Arc Welding Processes

4. Welding Position (See Appendix A - Glossary of Terms) - Because DC may be

because of the rapidly reversing magnetic field produced.

produces welds with

and a narrower weld

HIGHER BURN-OFF RATE,

COPYRIGHT 1998 THE ESAB GROUP, INC

Lesson 2 - Common Electric Arc Welding Processes